Elastomeric base for pressure vessels

ABSTRACT

An elastomeric base for a pressure vessel is configured to be adhesively secured to the bottom of the vessel in order to eliminate the problems caused by welding of steel legs. The base includes a surface configured to correspond with a curved surface of the compressor vessel. Advantageously, the base may be formed of an elastomeric material, a plastic, or of an elastomeric material co-molded with a ridged plastic.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority under 35 U.S.C. § 119 to the U.S. Provisional Application Ser. No. 60/540,847, filed on Jan. 30, 2004, which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to the field of pressure vessels used to store a fluid under pressure, including pressure vessels used in portable air compressors, and more particularly to an elastomeric base that is adhered to the pressure vessel.

BACKGROUND OF THE INVENTION

Many portable air compressors include a compressor mounted to an air storage tank supported by a steel pedestal having a plurality of legs welded to the bottom surface of the tank. The compressor compresses air which is stored in the air storage tank for use in powering air-powered tools, inflating tires, or the like. Typically, the air storage tank comprises a pancake-style pressure vessel having a generally flattened spherical shape. Alternately, the pressure vessel could comprise a vertical or horizontal pressure vessel, which comprises cylindrical vessels having hemispherical ends.

Welding of the legs to the air storage tank is inefficient for several reasons. Welding may cause leak points in the tank if the weld burns through the tank wall. In such cases, the pressure tank would fail pressure testing and may have to be discarded. Further, the welded steel legs may be damaged or bent during manufacturing or shipping or while being used. Damaged legs must be repaired or replaced by new legs re-welded to the air storage tank. Further, steel legs can scratch or mar floor surface requiring that each of the legs be provided with a protective foot or pad of non-abrasive material such as rubber or plastic, resulting in added cost in manufacturing the air compressor.

Consequently, it would be desirable to provide an air compressor including an air storage tank having a base which is not welded to the tank and which does not require protective pads or the like.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a base for a pressure vessel such as the air storage tank of an air compressor, which is adhesively secured to the pressure vessel thereby eliminating many of the problems caused by welding steel lets to such vessels. The base may be formed of an elastomeric material such as rubber, synthetic rubber, a plastic, an elastomeric material co-molded over a hard plastic, or the like.

In exemplary embodiments, the base comprises a single piece pedestal including a plurality of elongated legs. The single piece pedestal may have a surface contoured to fit the curved (e.g., hemispherical or cylindrical) surface of the pressure vessel so that the pedestal can be securely attached to the vessel via adhesive. In one specific embodiment, the single piece pedestal may comprise three or more prongs which are attached to feet for supporting the pressure vessel. In another specific embodiment, the single piece pedestal may comprise a ring shaped pedestal.

In other embodiments, the base comprises a pedestal having a plurality of individual base members or feet which are adhered to the pressure vessel. Each individual base member may include a surface configured to correspond with a curved form surface of the compressor tank.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:

FIG. 1 is an isometric view of an air compressor having a base in accordance with an exemplary embodiment of the present invention;

FIG. 2 is a bottom plan view of an air compressor having a base wherein a compressor tank of the air compressor has a footprint;

FIG. 3 is an exploded view of the air compressor shown in FIG. 2;

FIG. 4A and FIG. 4B are illustrations of the base shown in FIG. 2;

FIG. 5A and FIG. 5B are illustrations of a second base in accordance with an exemplary embodiment of the present invention; and

FIG. 6 is a bottom plan view of an air compressor having the base in FIG. 5A in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.

The present invention provides a base for a pressure vessel such as the air storage tank of an air compressor. The base is adhesively secured to the pressure vessel thereby eliminating many of the problems caused by welding steel legs to such vessels. In exemplary embodiments, the base may be formed of an elastomeric material such as rubber, synthetic rubber, a plastic, an elastomeric material co-molded over a hard plastic, or the like. In the following description, numerous specific descriptions are set forth in order to provide a thorough understanding of the present invention. It should be appreciated by those skilled in the art that the present invention may be practiced without some or all of these specific details. In some instances, well known process operations have not been described in detail in order not to obscure the present invention.

Referring now to FIG. 1, an air compressor 100 in accordance with an exemplary embodiment of the present invention is shown. The air compressor 100 includes a compressor 102, an air storage tank 104 and a base 106. The compressor 102 is mounted on the air storage tank 104 and provides compressed air, which is stored in the tank 104 for powering air-powered tools (e.g., nailers, paint sprayers, impact wrenches and the like). In accordance with the present invention, the base 106 is secured to the compressor tank 104 with an adhesive. It will be appreciated that various types of adhesives may be used for securing the base 106 to the steel surface of the air storage tank. For example, the adhesive may be applied to the tank 104 and/or the base 106 as a liquid or paste and allowed to dry after the base 106 is positioned on the tank 104. Alternately, the adhesive may comprise a two-sided tape which is applied to the base 104, and then used for adhering the base 106 to the tank 104. In exemplary embodiments, the base 106 may be formed of an elastomeric material such as rubber, synthetic rubber, a plastic, an elastomeric material co-molded over a hard plastic, or the like. In this manner, the base may enhance vibration dampening of the air compressor 100. The base 106 may also prevent scratching or marring of surfaces (e.g., floors, tabletops, or the like) supporting the air compressor and may prevent the air compressor 100 from sliding on such surfaces since the elastomeric material has a high coefficient of friction.

In an advantageous aspect of the present invention, the base 106, because it does not need to be welded to the air storage tank 104 during manufacture of the tank 104, may be attached to the tank with adhesive at any stage of the manufacturing process.

Referring now to FIGS. 2 and 3, an air compressor 200 having a base comprised of a single-piece pedestal in accordance with the present invention is described. As shown in FIG. 2, the air compressor 200 includes a compressor 202 mounted on a pancake-style air storage tank 204. The air storage tank 204 may be formed of steel and is preferably suitable for containing air at an elevated pressure. In exemplary embodiments, the compressor 202 may include an electric motor, an internal combustion engine, or the like for powering the compressor 202.

As shown, a condensate valve 208 may be located on the bottom of the air storage tank 204 for draining water from the tank 204. The base 206, which is secured to the air storage tank 204 with adhesive, may be configured to protect the condensate valve 208 from damage. For example, the base may include a foot member which extends at least partially around the condensate valve 208. In this embodiment, the base 206 may be molded with ridged plastic and at least partially elastomeric material such as natural rubber, synthetic rubber or the like, which is suitable for outer coating of a molded ridged plastic base. As a result, the base may be made more robust and less likely to be damaged or separated from the air storage tank 204.

As shown in FIG. 2, the air storage tank defines a footprint 210 for the air compressor 200. Preferably, the base 206 is configured to fit within the footprint. This configuration allows the overall size of the air compressor 200 to be reduced compared with air compressor having welded steel legs.

Referring now to FIG. 4A, a base 400 in accordance with an exemplary embodiment of the present invention is shown. The base 400 comprises a single-piece pedestal with having a plurality of feet. For example, in the embodiment illustrated, the base may include three elongated feet which are generally equidistant from each other. In the example, at least one elongated foot may include a C-shaped portion 402. The C-shaped portion 402 may extend generally around a condensate valve for protecting the condensate valve from damage. The base 400 may be constructed to have an upper surface contoured to fit the outer surface of a pressure vessel such as the air storage tanks 104, 204 shown in FIGS. 1 through 3.

Referring now to FIG. 4B, a bottom side view of a foot of the base 400 shown in FIG. 4A is illustrated. As shown, each foot 404 of the base 400 may have a bottom surface which includes a recess formed therein thereby reducing the material used for forming the foot 404. In this manner, less material is required for molding of the base 400.

In another embodiment of the present invention, the base may alternatively include a plurality of individual base members. Referring now to FIG. 5A through 5B, an individual base member 500 in accordance with the present invention is shown. The individual base member 500 has all the advantages of the single piece base discussed above. However, the individual base member 500 may be more cost effective because it requires less material to manufacture. Each base member 500 may be configured to have an upper surface contoured to fit an outside surface of the corresponding compressor tank via a suitable adhesive. Each base member 500 may be configured to have a bottom surface with a recess.

Referring now to FIG. 6, an air compressor 600 having a base including a plurality of individual base members such as the base members shown in FIGS. 5A and 5B is described. The air compressor 600 comprises a compressor unit 602, an air storage tank 604 to which individual base members 606 are attached. In accordance with the present invention, the individual base members 606 are preferably secured to the compressor tank 604 via an adhesive.

In FIGS. 1 through 6, the air compressors illustrated comprise portable air compressor having a pancake-style air storage tanks. However, it is contemplated that bases in accordance with the present invention may be provided for air compressors having other types of air storage tanks, including vertical and horizontal tanks. It is further contemplated that in an alternative embodiment, the base of the present invention may be used for supporting other types of pressure vessel such as propane tanks, water tanks, gasoline tanks, and the like, without departing from the scope and spirit of the present invention.

It is believed that the present invention and many of its attendant advantages will be understood by the forgoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof, it is the intention of the following claims to encompass and include such changes. 

1. A portable air compressor, comprising: a air storage tank forming a generally hemispherical shape, the air storage tank for containing air at an elevated pressure; a base coupled to the compressor vessel, the base comprising a plurality of feet configured to be adhesively secured to the air storage tank, wherein the pedestal includes a surface configured to correspond with the shape of the surface of the air storage tank.
 2. The portable air compressor as described in claim 1, wherein each of the plurality of feet is secured to the air storage tank generally equidistant from an adjacent foot in the pedestal.
 3. The portable air compressor as described in claim 1, wherein the pedestal includes vibration dampening material.
 4. The portable air compressor as described in claim 1, further comprising a valve for draining condensate.
 5. The portable air compressor as described in claim 4, wherein the pedestal is constructed to at least partially extend around the valve for protection.
 6. The portable air compressor as described in claim 3, wherein the pedestal includes outer-coating material which has high coefficient of friction for preventing the portable air compressor from skidding.
 7. The portable air compressor as described in claim 1, wherein the pedestal is molded with ridged plastic.
 8. The portable air compressor as described in claim 7, wherein the pedestal is co-molded with at least partially elastomeric material.
 9. The portable air compressor as described in claim 1, wherein the air storage tank defines a footprint and the pedestal is configured to be within the footprint.
 10. The portable air compressor as described in claim 1, wherein each of the plurality of feet is an elongated foot connected to form the pedestal.
 11. A pressure vessel, comprising: a pedestal coupled to the pressure vessel, the pedestal including a plurality of base members configured to be adhesively secured to the pressure vessel, each of the plurality of base members including a first surface configured to correspond with a curved form surface of the pressure vessel.
 12. The pressure vessel as described in claim 11, wherein each of the plurality of base members includes vibration dampening material.
 13. The pressure vessel as described in claim 11, wherein each of the plurality of base members is molded with ridged plastic.
 14. The pressure vessel as described in claim 11, wherein each of the plurality of base members includes a second surface with a recess.
 15. A base for a pressure vessel, comprising: a pedestal for supporting the pressure vessel, the pedestal including a plurality of feet configured to be adhesively secured to the pressure vessel, wherein the pedestal includes a surface configured to correspond with a generally curved surface of the pressure vessel.
 16. The base for a pressure vessel as described in claim 16, wherein the pedestal is constructed to support the pressure vessel to rest on a flat surface.
 17. The base for a pressure vessel as described in claim 16, wherein each of the plurality of feet is secured to the pressure vessel substantially equidistant from an adjacent foot included in the plurality of feet.
 18. An air compressor, comprising: means for containing air at an elevated pressure; and means for supporting the air containing means, wherein the supporting means is secured to the air containing means via a adhesive.
 19. The air compressor as described in claim 18, wherein the supporting means includes a first surface configured to correspond with a generally curved surface of the containing air means and a second surface with a recess.
 20. The air compressor as described in claim 18, wherein the supporting means is configured to have a circular shape. 